Dye-sensitizing solar cell, method for manufacturing dye-sensitizing solar cell and solar cell module

Abstract

A dye-sensitizing solar cell comprising: a first substrate whose surface is at least conductive; a second substrate on which a conductive layer is formed, the second substrate being transparent, the first and second substrates being spaced by a distance with the conductive surfaces of the first and second substrates opposite to each other; a semiconductor layer having a dye adsorbed thereon, the semiconductor layer being formed on one of the conductive surfaces; a glass frit for sealing peripheral edges of the first and second substrates; and a redox electrolyte which is filled between the first and second substrates.

What is claimed is:  
     
       1. A dye-sensitizing solar cell comprising: 
       a first substrate, and a first conductive layer formed on the first substrate;  
       a second substrate, and a second conductive layer formed on a surface of the second substrate, the second substrate being transparent, the first and second substrates being spaced by a distance with the first and second conductive layers on the first and second substrates, respectively, facing each other;  
       a semiconductor layer having a dye adsorbed thereon, the semiconductor layer being formed on one of the conductive layers;  
       a glass frit for sealing peripheral edges of the first and second substrates; and  
       a redox electrolyte which is filled between the first and second substrates, wherein the redox electrolyte is formed so as to be provided between and directly contact each of (a) the semiconductor layer, and (b) the conductive layer formed on the substrate that the semiconductor layer is not formed on.  
     
     
       2. The solar cell of  claim 1 , in which the glass frit is a mixture of a glass powder and an acrylic resin. 
     
     
       3. The solar cell of  claim 2 , in which the glass powder is made of ceramics; PbO, B 2 O 3 , Na 2 O, BaO, SiO 2  or a mixture thereof; or crystalline glass powders. 
     
     
       4. The solar cell of  claim 1 , in which the semiconductor layer is made of titanium oxide particles. 
     
     
       5. The solar cell of  claim 1 , in which the semiconductor layer has a width of 3 to 20 mm. 
     
     
       6. A method for manufacturing a dye-sensitizing solar cell, the method comprising: 
       forming a semiconductor layer on a first or second substrate;  
       opposing the first and second substrates to each other in spaced-apart relationship;  
       sealing peripheral edges of the first and second substrates with a glass frit to form a closed space between the first and second substrates;  
       forming openings for communicating the closed space with the outside in at least two positions;  
       circulating a dye solution within the closed space through the openings so that the dye is adsorbed on the semiconductor layer; and  
       discharging remaining dye solution and then injecting a redox electrolyte into the closed space.  
     
     
       7. The method of  claim 6 , in which the step of forming the semiconductor layer comprises coating a suspension containing semiconductor particles on a surface of the first or second substrate and calcining and curing the coated suspension, the step of sealing the peripheral edges of the first and second substrates comprises coating a pasty glass frit containing a binder on the peripheral edges of the first and second substrates, temporally calcining the pasty glass frit to remove the binder and then substantially calcining the glass frit to seal the peripheral edges of the first and second substrates, wherein the steps of calcining the suspension and substantially calcining the glass frit are conducted simultaneously. 
     
     
       8. The method of  claim 7 , in which the step of temporally calcining the glass frit is conducted under a temperature profile in which the temperature is raised to a first temperature with a first temperature gradient and raised from the first temperature to a second temperature with a second temperature gradient different than the first temperature gradient, and the second temperature is maintained for a period of time and then lowered with a third temperature gradient. 
     
     
       9. The method of  claim 7 , in which the step of calcining the suspension and substantially calcining the glass frit simultaneously is conducted under a temperature profile in which the temperature is raised to a third temperature with a fourth temperature gradient, and the third temperature is maintained for a period of time and then lowered with a fifth temperature gradient. 
     
     
       10. The method of  claim 7 , in which the suspension and the glass frit are calcined simultaneously with oxygen fed into the closed space via the openings. 
     
     
       11. The method of  claim 6 , in which the step of forming the openings for communicating the closed space with the outside is performed by forming openings in one of the first and second substrates. 
     
     
       12. The method of  claim 6 , in which the step of forming the openings for communicating the closed space with the outside is performed by inserting tubular members into the closed space through the glass frit. 
     
     
       13. A solar cell module comprising a plurality of dye-sensitizing solar cells arrayed in a plane and electrically connected with metal wires, each of the dye-sensitizing solar cells being defined in  claim 1 . 
     
     
       14. A method for manufacturing a dye-sensitizing solar cell, the method comprising: 
       forming a semiconductor layer so as to be supported by a first substrate;  
       opposing the first substrate to a second substrate in a spaced-apart relationship;  
       sealing the first and second substrates with a seal in a manner so as to form a closed space between the first and second substrates;  
       forming at least one opening for communicating the closed space with the outside;  
       introducing a dye solution into the closed space through the opening so that the dye is adsorbed on the semiconductor layer; and  
       discharging remaining dye solution from the closed space and thereafter injecting a redox electrolyte into the closed space.  
     
     
       15. The method of  claim 14 , wherein forming the semiconductor layer comprises coating a suspension containing semiconductor particles on a surface of the first or second substrate and calcining and curing the coated suspension, and sealing the first and second substrates comprises coating a pasty glass frit containing a binder on the peripheral edges of the first and second substrates, temporally calcining the pasty glass frit to remove the binder and then at least partially calcining the glass frit to be cured to form the seal. 
     
     
       16. The method of  claim 15 , wherein the steps of calcining the suspension and at least partially calcining the glass frit are conducted simultaneously. 
     
     
       17. The method of  claim 14 , where the seal comprises glass frit. 
     
     
       18. A dye-sensitizing solar cell comprising: 
       a first substrate, and a first conductive layer formed on the first substrate;  
       a second substrate, and a second conductive layer formed on a surface of the second substrate, one of the first and second substrates being transparent;  
       at least one spacer interposed between the first and second conductive layers whereby the first and second substrates are spaced by a distance with the first and second conductive layers facing each other;  
       a semiconductor layer having a dye adsorbed thereon, the semiconductor layer being formed on the first conductive layer;  
       a glass frit provided between the first and second conductive layers to surround the semiconductor layer and define a closed space between the semiconductor layer and the second conductive layer;  
       a redox electrolyte for filling up the closed space; and  
       wherein the spacer is buried in the glass frit.  
     
     
       19. A solar cell module comprising a plurality of dye-sensitizing solar cells arrayed in a plane, wherein each solar cell includes the solar cell of  claim 18 , the spacer of each solar cell is conductive, and two solar cells adjacent to each other are electrically connected in series where the spacer is in contact with the first conductive layer of one solar cell and the second conductive layer of the other solar cell. 
     
     
       20. A method of manufacturing a solar cell module of  claim 19 , the method comprising: 
       forming a plurality of semiconductor layers on a first substrate having plural first conductive layers so that the semiconductor layers are arranged in spaced-apart relation with each other;  
       opposing, in spaced apart relation, the first substrate to a second substrate having plural second conductive layers;  
       surrounding each semiconductor layer with a conductive spacer and glass frit to define closed spaces between the semiconductor layers and the second substrate wherein each spacer is buried in the glass frit;  
       forming openings for communicating each closed space with the outside in at least two positions;  
       circulating a dye solution within each closed space through the openings so that the dye is adsorbed on each semiconductor layer; and  
       discharging remaining dye solution and then injecting a redox electrolyte into each closed space.